05 400Ex topend build.. - Honda Foreman Forums : Rubicon, Rincon, Rancher and Recon Forum

350rancherboy · 03-28-2011, 07:11 PM

Building a 400ex for my ridin buddy. Never done this style motor so HANG ON! Will try to get pix soon, Ordered a clymer manual (have SOMETHIGN to go buy lol) hopefully its here in the comming days. So far I have valve cover off, chain has a TIDBIT of play in it dunno how to exactly get the cam/chain off so im waiting for my book to come in

Thanks guys

Maybe someone can tell me how much is too much play in the chain, also, I broke a lnog 8mm headed bolt off, how ya think I can get it out...

Helmut · 03-28-2011, 07:39 PM

Give me a few minutes to upload it and I will post the link to a PDF copy of the service manual.

Helmut · 03-28-2011, 07:56 PM

Here you go.

2005-2009 TRX400EX Service Manual

350rancherboy · 03-28-2011, 08:38 PM

Dangg...

Spent almost 40$ on one, oh well i'll have a look see

THANKS

Sterkview_dairy · 03-28-2011, 08:46 PM

me personally i like the papers toflip through with my dirty fingers that is wise i have a book for both my 450 and 300. but thanks for my 300 pdf helmut.

350rancherboy · 03-28-2011, 09:03 PM

Wow! I wish I asked here first (should've known better). Thanks alot helmut!

I like the books too but this would've saved me $ and its a Honda book (i cheaped out and got clymer..)..

Any more downloadable manuals for honda atvs? thats really nice

350rancherboy · 03-29-2011, 07:06 PM

Didnt know how much play was too much play in the timing chain..

I talked to my atv guy he said it shouldnt have any (it did).

Got parts boxed up and ready to take up there to insure that I BUY the right parts and see how bad cyl. piston are..

350rancherboy · 03-29-2011, 07:08 PM

mo pix im pretty excited to know I did it/could do it again

not nearly as bad as I thought, i just jumped in

350rancherboy · 04-07-2011, 07:14 PM

Need help.

Book calls for a specail tool to get the sprocket off to replace the timing chain, OR use a old sprocket for a 'tool'.

I dont have either, Im going to talk to my ATV guy and see if he has one.

Is there a homebrew way? I gotta replace the timing chain and this has to come off

HELP.

I thought about taking the impact to it but even that would spin the motor over (badd)

Helmut · 04-07-2011, 07:40 PM

Are you trying remove the oil pump gear and the primary drive gear? If so, just stick a piece of aluminum down between the primary drive gear and the big gear on the back on the clutch basket. When you turn the nut, the aluminum will bind the gears and hold them. You may even be able to use a penny or something. Just make sure whatever you use, is soft, so it won't damage the teeth on the gears.

03-28-2011, 07:11 PM	#1 (permalink)
350rancherboy Honda Lover Join Date: Nov 2010 Posts: 289	05 400Ex topend build.. Building a 400ex for my ridin buddy. Never done this style motor so HANG ON! Will try to get pix soon, Ordered a clymer manual (have SOMETHIGN to go buy lol) hopefully its here in the comming days. So far I have valve cover off, chain has a TIDBIT of play in it dunno how to exactly get the cam/chain off so im waiting for my book to come in Thanks guys Maybe someone can tell me how much is too much play in the chain, also, I broke a lnog 8mm headed bolt off, how ya think I can get it out... __________________ ATVLESS

03-28-2011, 08:38 PM	#4 (permalink)
350rancherboy Honda Lover Join Date: Nov 2010 Posts: 289	Dangg... Spent almost 40$ on one, oh well i'll have a look see THANKS __________________ ATVLESS

03-28-2011, 08:46 PM	#5 (permalink)
Sterkview_dairy Honda Red Wing Rider Join Date: Jan 2010 Location: Embro Ont Canada Posts: 651	me personally i like the papers toflip through with my dirty fingers that is wise i have a book for both my 450 and 300. but thanks for my 300 pdf helmut. __________________ DGL#1 for Sale TRX 450S Foreman 01-28 Mudbugs on ITP Type 5, Warn 424, Quadrax Disc Brake kit, Triple lift front. Prefex RearWarn RT30 wireles remote, Amsteel Blue, Floor Boards, ODI Grips, JD Lights, Custom Built Stick Stoppers, Bash Plate, Skid Plate. TRX 300FW Fourtrax 88-26 Mudbugs on ITP Type 5, Quadrax Disc Brake Kit, 450 shocks front, Big Red Rear with built in lift, ODI Grips, Floorboards TRX 500ES Foreman 07 26 Mudbugs, HL+Prefex.

03-28-2011, 09:03 PM	#6 (permalink)
350rancherboy Honda Lover Join Date: Nov 2010 Posts: 289	Wow! I wish I asked here first (should've known better). Thanks alot helmut! I like the books too but this would've saved me $ and its a Honda book (i cheaped out and got clymer..).. Any more downloadable manuals for honda atvs? thats really nice __________________ ATVLESS

03-29-2011, 07:06 PM	#7 (permalink)
350rancherboy Honda Lover Join Date: Nov 2010 Posts: 289	Didnt know how much play was too much play in the timing chain.. I talked to my atv guy he said it shouldnt have any (it did). Got parts boxed up and ready to take up there to insure that I BUY the right parts and see how bad cyl. piston are.. Attached Thumbnails __________________ ATVLESS

03-28-2011, 07:39 PM	#2 (permalink)
Helmut Honda Red Wing Rider Join Date: Jan 2010 Posts: 742	Give me a few minutes to upload it and I will post the link to a PDF copy of the service manual.

03-28-2011, 07:56 PM	#3 (permalink)
Helmut Honda Red Wing Rider Join Date: Jan 2010 Posts: 742	Here you go. 2005-2009 TRX400EX Service Manual

03-29-2011, 07:08 PM	#8 (permalink)
350rancherboy Honda Lover Join Date: Nov 2010 Posts: 289	mo pix im pretty excited to know I did it/could do it again not nearly as bad as I thought, i just jumped in Attached Thumbnails __________________ ATVLESS

04-07-2011, 07:14 PM	#9 (permalink)
350rancherboy Honda Lover Join Date: Nov 2010 Posts: 289	Need help. Book calls for a specail tool to get the sprocket off to replace the timing chain, OR use a old sprocket for a 'tool'. I dont have either, Im going to talk to my ATV guy and see if he has one. Is there a homebrew way? I gotta replace the timing chain and this has to come off HELP. I thought about taking the impact to it but even that would spin the motor over (badd) Attached Thumbnails __________________ ATVLESS

04-07-2011, 07:40 PM	#10 (permalink)
Helmut Honda Red Wing Rider Join Date: Jan 2010 Posts: 742	Are you trying remove the oil pump gear and the primary drive gear? If so, just stick a piece of aluminum down between the primary drive gear and the big gear on the back on the clutch basket. When you turn the nut, the aluminum will bind the gears and hold them. You may even be able to use a penny or something. Just make sure whatever you use, is soft, so it won't damage the teeth on the gears.

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